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FORWARD:
This manual is an instrument designed to direct Quality Control personnel in their duties to maintain the quality of products produced by Perfection Metal Products. The following procedures are required in production of government contract fabrications specifying MIL-I-45208A, MIL-STD-45662, or any other contract requirements. This manual is subject to review at twelve month intervals for updating deletions or additions as required. The reviewing and updating of our manual will be the responsibility of the Quality Control Manager.
This procedure establishes a system to assure that all applicable manufacturing, inspection, and shipping information and specifications are available throughout the processing of the order.
Procedure:
Upon receipt of a purchase order for a part not previously manufactured, a master job card will be made up. The master card contains job history on one side and manufacturing procedures on the other side. The manufacturing procedures side of the card includes the customer name, part number, current revision, applicable QC codes, and specifications for finishing, packaging and shipping. Copies of the job traveler are available for inspection at Perfection Metal Products. Job travelers for government jobs will be issued on green paper for easy identification. Along with the job traveler, a copy of the traveling inspection report is issued and a current copy of the blueprint. A copy of the traveling inspection report is included in this manual in exhibit A.
This procedure establishes a system to assure that only current revisions of blueprints are used in the production of parts.
Procedure:
When an order is received it is reviewed to assure the revision level of the parts has not changed. If a change has occurred, the old copies of the blueprints are stamped OBSOLETE with a 1/2" red stamp across the title block. One copy of down revision prints will be kept on file in the front office for reference and as a record of change. Revision changes affecting jobs in process will be incorporated by the Quality Control Manager and the Manufacturing Manager. They will report to the front office the extent of changes that may affect estimated production hours or delivery schedules.
This procedure establishes a system to inspect, identify, and label accepted material. This procedure will also define the handling of discrepant or sub-standard material.
Procedure:
Inspection of inbound material will be the responsibility of the Quality Control Manager. All material for government contract jobs will be ordered on a purchase order that has the same number as the job number. The material will be physically inspected and certifications will be checked for conformance to drawings and specifications. Material that passes inspection will be tagged with the job number, customer name, part number, material description, and number of sheets or parts. Only tagged material can be used for production of government contract work. A receiving inspection report will be filled out and filed in the master job folder in the front office. If required by the specific contract, independent laboratory analysis of material will be done to verify the certification.
A copy of the independent analysis will be filed in the master job folder. See exhibit B for an example of the receiving inspection report and material tag. Material that is found to be non-conforming to specifications will not be tagged for a job. Absence of certifications or any other required documents will be cause for rejection of material. Rejected material will be returned to the supplier for replacement. The return of discrepant material will be the responsibility of the Manufacturing Manager.
This procedure establishes a system to assure and record the quality of piece parts or sub-assemblies throughout manufacturing.
Procedure:
First article and AQL inspection will be the responsibility of the Quality Control Manager. Parts will be inspected at the operations listed on the Traveling Inspection Report that accompanies each job order. First article part samples will be checked 100% for the operation being performed, both for accuracy and completeness. The AQL level that is used for in process inspection will be determined by the customers specifications. The completed Traveling Inspection Record will be filed in the master job folder in the front office. Discrepant material will be red tagged as rejected and routed to the Material Review Quarantine Area.
This procedure establishes a system for inspection before subcontract processing to assure and record the quality and completeness of piece parts or sub-assemblies.
Procedure:
When in-house manufacturing of a job is complete the parts must be inspected before they can be sent out for sub-contract processing. Inspection will be the responsibility of the Quality Control Manager. The inspection will be to the AQL level required by the customer, and the results will be recorded on the traveling inspection record. Discrepant material will be red tagged as rejected and routed to the Material Review Quarantine area.
This procedure establishes a system to inspect and assure that all manufactured parts meet customer specifications, are complete, and include all the required certifications, samples, and other paperwork.
Procedure:
Each job of either piece parts or sub-assemblies must be final inspected before being transferred to the packaging area. Final inspection will be the responsibility of the Quality Control Manager. Prior to starting the final inspection, the inspector will get the master job folder from the front office. As the final inspection is done the inspector will have the purchase order at hand and will confirm that all QC codes have been satisfied, and that all the required samples and certifications are complete. A random sampling of parts will be taken from the job and inspected to the AQL sampling plan required by the contract.
The results of the sample inspected will be recorded on our Documented Attributes and Inspection Plan form. A sample of this form is included in this document as exhibit C. The inspection findings will be recorded on the Final Inspection Report, a copy of which will go into the master job folder in the front office. Individual inspection reports will be made for each job inspected and filed by customer and part number. The report will include part revision or E/C level, each dimension inspected, and the quantity accepted or rejected. Copies of final inspection results will be available for customer viewing in either the front office or in the QC area. A copy of the Final Inspection Report is included in this document as Exhibit C. Jobs that pass inspection will be QC stamped on the job traveler and be routed to packaging. Parts or sub-assemblies that do not pass final inspection will be red tagged as rejected and routed to the material review quarantine area.
This procedure establishes a system for customers to inspect parts or assemblies being manufactured on their contracts at our facility.
Procedure:
Prior to customer or government source inspection, all parts will be final inspected and stamped as passed on the job traveler. An inspection area will be provided for source inspection and any Purchase Orders, Inspection Reports, or other required paperwork will be available to the inspector.
This procedure establishes a system to assure that adequate protection is provided to all parts being shipped to customers and that all outgoing shipments meet or exceed the customers packaging specifications.
Procedure:
Shipping inspection will be the responsibility of the Quality Control Manager. Packaging materials and containers will be inspected to make sure that they meet customer specifications. After containers are sealed and before they are shipped, they will be inspected for all applicable marking and correct shipping address.
This procedure establishes a system for reviewing rejected material, defining actions required to make the parts meet specifications, or assuring timely disposal of scrapped material.
Procedure:
Review of rejected material will be done by the Material Review board consisting of Quality Control, Manufacturing, and the Vice President. All rejected material will be reviewed and dispositioned before it is released from the quarantine area. Parts or sub-assemblies that can be reworked to meet customer specifications will be routed to the appropriate work station with detailed rework instructions and inspected upon completion of rework. A copy of the rework instruction form is included in this document as exhibit D. The Material Review Board will also make recommendations for process changes that can avoid reoccurrence of the problem for future jobs.
Rejected parts that are not able to be reworked, but only have minor defects that do not affect fit, function, safety, or reliability will be held for customer review. Decisions on minor defects will be made by a government or customer representative after reviewing the material and receiving Material Review Board recommendations. Parts dispositioned "use as is" will be routed back into production and a record of the deviation will be made in the inspection records. Parts that are found to be not reworkable will be scrapped. The Quality Control Manager will be responsible for identifying the parts by signing off the red tag as scrap. He will also make sure that the parts are physically removed from the quarantine area and disposed of. The job traveler will be returned to the front office and a new job number will be issued to remake the required quantity of scrapped parts. The new job will incorporate all corrective action, revised routing instructions, and notations about previous defects that caused scrapping.
This procedure establishes a system of segregating parts or sub-assemblies that do not meet customer specifications pending review and disposition.
Procedure:
Parts that do not pass inspection will be routed to the Material Review Quarantine Area and be held there until they are dispositioned. Control of the Material Review Quarantine Area will be the responsibility of the Quality Control Manager. Under no circumstances will any parts be moved from the Quarantine area without disposition and routing instructions.
This procedure establishes a standard sampling plan to be used in inspection of parts manufactured for government contracts.
Procedure:
A random sample of parts will be drawn from each job according to the quantity specified in MIL-STD-105-E (Sampling Plan for inspection by Attributes). All contracts will be inspected by this plan unless otherwise specified . Other sampling and inspection criteria are available upon written customer request.
This procedure establishes a system to assure that all tooling, jigs, or fixtures that are used in manufacturing or inspection are properly calibrated and marked for identification.
Procedure:
When tooling, jigs, or fixtures are made for either manufacturing or inspection they will be 100% inspected before being used. If they pass, they will be marked with the customer name, part number, and revision or E/C level. Rechecking will be done periodically on a schedule set up by the Quality Control Manager. Immediate reinspection will be required if parts made using the tool, jig, or fixture fail inspection.
This procedure establishes a system to assure that measuring devices that are used for inspection are properly calibrated and sets up a schedule for maintaining calibration.
Procedure:
Calibration of inspection devices will be the responsibility of the Quality Control Manager. All inspection tools will be marked with the tool number, most recent calibration date, and the date that the next calibration is due. The Quality Control Manager will be responsible for maintaining a master calibration log book that will detail individual calibration history on each instrument and National Bureau of Standards certification numbers. The calibration schedule will meet or exceed the requirements set forth in MIL-C-45662 depending on customer requirements. Any calibration that cannot be done at this facility will be sent out to an accredited laboratory.
This procedure establishes a system for inspecting, identifying, and storing material supplied from government sources for use on a government contract
Procedure:
All incoming consigned material will go through receiving inspection as detailed in Procedure #3 of this manual and be tagged for identification. The supplier of the consigned material will be immediately notified if the supplied material is damaged, if the quantity is incorrect, or if the material does not meet the specifications required by the contract. Material that passes inspection will be kept segregated from production until it is required for the job that it was supplied for. Material will be periodically re-inspected to assure that it is not being damaged or deteriorating.